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Abstract:

A system for producing a hot-filled softgel capsule utilizes a chilled
liquid. The chilled liquid is routed through a chilled liquid conveyor
tray into a chilled liquid bath. The chilled liquid conveyor tray directs
the flowing chilled liquid into a flowing chilled liquid layer. Softgel
capsules having a heated fill material are deposited in the flowing
chilled liquid layer. The chilled liquid layer cools the capsule by
transferring heat from the capsule to the chilled liquid. The flowing
chilled liquid layer transports the capsule out of the chilled liquid
conveyor tray into a chilled liquid bath. A capsule transfer conveyor
transports the capsule out of the chilled liquid bath to a chilled liquid
removal device. The chilled liquid removal device removes the chilled
liquid from the capsule.

Claims:

1.-9. (canceled)

10. A system for cooling a hot-filled softgel capsule (50) where a capsule
(20) is formed by encasing a fill material (10) held at a fill material
temperature between two gelatin bands sealed together at a sealing
temperature, comprising:a chilled liquid conveyor tray (100) formed with
a base (120), at least one sidewall (110), a chilled liquid influent port
(150), and a discharge edge (160), wherein the sidewall (110) is
connected to and surrounds a portion of the base (120) thereby forming an
interior surface (130) and an exterior surface (140), the chilled liquid
influent port (150) extends from the exterior surface (140) to the
interior surface (130), and the discharge edge (160) connects the
interior surface (130) to the exterior surface (140), wherein a chilled
liquid (200) enters the chilled liquid conveyor tray (100) at a chilled
liquid temperature through the chilled liquid influent port (150) and
forms a flowing chilled liquid layer (170) having a flowing chilled
liquid layer depth (172) and a liquid layer flow rate, whereby the
capsule (20) contacts the flowing chilled liquid layer (170), heat flows
from the capsule (20) to the chilled liquid (200), and the discharge edge
(160) discharges the capsule (20) and the chilled liquid (200) out of the
chilled liquid conveyor tray (100).

12. The system for cooling a hot-filled softgel capsule (50) of claim 10,
further including a chilled liquid tank (300) containing the chilled
liquid (200) thereby creating a chilled liquid bath (310), wherein(A) the
discharge edge (160) is positioned relative to the chilled liquid bath
(310) so that the chilled fluid (200) and the capsule (20) flow from the
chilled liquid conveyor tray (100) to the chilled liquid tank (300);
and(B) the chilled liquid tank (300) has a capsule transfer conveyor
(320) having a transfer conveyor submerged portion (330), a transfer
conveyor inclined portion (340), and a transfer conveyor chilled liquid
removal portion (350); wherein(i) the transfer conveyor submerged portion
(330) captures the capsule (20) as the capsule (20) falls through the
chilled liquid (200),(ii) the transfer conveyor inclined portion (340)
transports the capsule (20) out of the chilled liquid bath (310),
and(iii) the transfer conveyor chilled liquid removal portion (350) has a
chilled liquid removal device (352) and a discharge end (354), wherein
the chilled liquid removal device (352) cleans a portion of the chilled
liquid (200) from the capsule (20) and the capsule (20) is transported
off the capsule transfer conveyor (320) at the capsule discharge end
(354).

13. The system for cooling a hot-filled softgel capsule (50) of claim 11,
further including a chilled liquid tank (300) containing the chilled
liquid (200) thereby creating a chilled liquid bath (310), wherein(A) the
discharge edge (160) is positioned relative to the chilled liquid bath
(310) so that the chilled fluid (200) and the capsule (20) flow from the
chilled liquid conveyor tray (100) to the chilled liquid tank (300);
and(B) the chilled liquid tank (300) has a capsule transfer conveyor
(320) having a transfer conveyor submerged portion (330), a transfer
conveyor inclined portion (340), and a transfer conveyor chilled liquid
removal portion (350), wherein(i) the transfer conveyor submerged portion
(330) captures the capsule (20) as the capsule (20) falls through the
chilled liquid (200),(ii) the transfer conveyor inclined portion (340)
transports the capsule (20) out of the chilled liquid bath (310),
and(iii) the transfer conveyor chilled liquid removal portion (350) has a
chilled liquid removal device (352) and a discharge end (354), wherein
the chilled liquid removal device (352) cleans a portion of the chilled
liquid (200) from the capsule (20) and the capsule (20) is transported
off the capsule transfer conveyor (320) at the capsule discharge end
(354).

14. The system for cooling a hot-filled softgel capsule (50) of claim 10,
wherein the chilled liquid layer depth (172) is between approximately 0.5
inches and approximately 2 inches.

15. The system for cooling a hot-filled softgel capsule (50) of claim 10,
wherein the liquid layer flow rate is between approximately 1 gallon per
minute and approximately 30 gallons per minute.

16. The method of cooling a hot-filled softgel capsule of claim 10,
wherein the chilled liquid removal device (352) is an air knife which
blows pressurized gas onto the capsule (20) to substantially remove the
chilled liquid (200).

17. A system for cooling a hot-filled softgel capsule (50) where a capsule
(20) is formed by encasing a fill material (10) held at a fill material
temperature between two gelatin bands sealed together at a sealing
temperature, comprising:a chilled liquid tank (300) filled with the
chilled liquid (200) thereby creating a chilled liquid bath (310) at a
chilled liquid bath temperature, wherein the capsule (20)(i) drops into
the chilled liquid bath (310),(ii) sinks, and(iii) transfers heat to the
chilled liquid bath (310) because the chilled liquid bath temperature is
less than the fill material temperature, and the chilled liquid tank
(300) has a capsule transfer conveyor (320) for controlling the egress of
the capsule (20) from the chilled liquid tank (300), wherein the capsule
transfer conveyor (320) has a transfer conveyor submerged portion (330),
a transfer conveyor inclined portion (340), and a transfer conveyor
chilled liquid removal portion (350), and wherein,(a) the transfer
conveyor submerged portion (330) captures the capsule (20) as the capsule
(20) falls through the chilled liquid (200),(b) the transfer conveyor
inclined portion (340) transports the capsule (20) out of the chilled
liquid bath (310), and(c) the transfer conveyor chilled liquid removal
portion (350) has a chilled liquid removal device (352) and a discharge
end (354), wherein the chilled liquid removal device (352) cleans a
portion of the chilled liquid (200) from the capsule (20) and the capsule
(20) is transported off the capsule transfer conveyor (320).

18. The method of cooling a hot-filled softgel capsule of claim 17,
wherein the chilled liquid removal device (352) is an air knife which
blows pressurized gas onto the capsule (20) to substantially remove the
chilled liquid (200).

Description:

TECHNICAL FIELD

[0001]The present invention generally relates to softgel capsule
manufacturing and, more particularly, relates to a method for producing
and a system for cooling softgel capsules formed by encapsulating a hot
fill material in a film followed by cooling the capsule with a chilled
liquid.

BACKGROUND OF THE INVENTION

[0002]Soft capsules generally consist of a shell which is produced, for
example, by extending a mixture of gelatin, plasticizer, and water into a
thin sheet, film, or band. Capsules formed from such a sheet hold a wide
variety of substances. The shell of a soft capsule is typically produced,
for example, by adding, to an aqueous gelatin melt, a plasticizer in an
amount of 30-40 wt % with respect to the gelatin, and drying the shell
until the water content becomes 5-10% by weight.

[0003]One manufacturing process used to make soft capsules uses a rotary
die machine to encapsulate a fill material between two films. The rotary
die method is more commonly referred to as the Scherer process. In this
process, for example, two separate, continuous bands or sheets of gelatin
are feed into the rotary die machine. The fill material or ingredients
are simultaneously injected by an injector wedge between the two gelatin
bands as the bands are drawn between two opposing, rotating dies or
rollers. The rotating dies each have a plurality of cavities which align
on opposing sides of the gelatin bands. The bands are pinched between the
dies with each die cavity essentially forming one-half of a capsule.
Thus, the gelatin bands and the fill material are introduced between the
rotating dies where the fill material is sealed within the two halves of
gelatin. Once formed, the gelatin capsule is ejected from the rotating
die machine. Subsequent processes are used to prepare the gelatin capsule
for packaging and shipment.

[0004]As used in this specification and in the claims, the term gelatin is
meant to include not only the mammalian gelatin such as bovine and
porcine, but also fish gelatins and other non-gelatin materials that are
useful in soft capsule preparation. Those skilled in the art readily
appreciate that there are a number of non-gelatin materials that can be
used for soft capsule preparation such as modified starches and
carrageenans, modified starches alone, and other compositions that are
well known to those skilled in the art.

[0005]Gelatin is a substantially pure protein food ingredient, obtained by
the thermal denaturation of collagen, which is the most common structural
material and most common protein in animals. Gelatin forms thermally
reversible gels with water, which gives gelatin products unique
properties, such as reversible sol-gel transition states at near
physiologic temperatures. Therefore, gelatin encapsulation of a fill
material having an elevated temperature is problematic.

[0006]The temperature influence on the gelatin's physical properties
imposes significant process challenges for encapsulating fill materials
that are heated prior to the encapsulation process. This is particularly
true when the fill material approaches, or exceeds, a gelatin sealing
temperature. Capsules having hot fill materials readily deform when they
make contact with external surfaces. The deformation is due to the
elevated temperature of the fill material which maintains the gelatin at
a temperature where the gelatin is very soft and pliable. While
deformation, by itself, does not generally result in any deleterious
problems with how the capsule functions, permanent deformation is
unacceptable from a product aesthetics perspective. That is, consumers
respond negatively to poor shape uniformity, finding faceted or flattened
capsules unacceptable. Therefore, capsules that are deformed or that lack
of shape uniformity are not merchantable.

[0007]The soft capsule manufacturing industry has long sought a softgel
manufacturing processes that can encapsulate hot fill materials within
gelatin. The numerous advantages of the gelatin capsule may be expanded
by enlarging the variety of fill materials that may be encapsulated. In
addition, there is a need for a manufacturing process that is capable of
encapsulating hot fill materials at a high rate, yet can provide
aesthetically pleasing, uniformly formed capsules which do not
permanently deform during subsequent handling or packaging. Finally,
there is a need for a softgel manufacturing process that is
environmentally friendly, consumer safe, and cost effective. The present
invention provides these aforementioned qualities by contacting the
capsule with a chilled liquid immediately subsequent to capsule
formation.

SUMMARY OF THE INVENTION

[0008]In its most general configuration, the present invention advances
the state of the art with a variety of new capabilities and overcomes
many of the shortcomings of prior devices in new and novel ways. In its
most general sense, the present invention overcomes the shortcomings and
limitations of the prior art in any of a number of generally effective
configurations. The instant invention demonstrates such capabilities and
overcomes many of the shortcomings of prior methods in new and novel
ways.

[0009]A primary mixing system may be used to mix, homogenize, and heat one
or more fill materials. The fill material may be pumped to a secondary
mixing system which heats the fill material to a fill material
temperature prior to being fed to an encapsulation pump head assembly.
The encapsulation pump head assembly may receive the fill material from
the secondary mixing system. A pair of rotating dies presses the fill
material between the first and second gelatin bands at the gelatin bands
sealing temperature, thus forming a capsule. In one embodiment of the
instant invention, the fill material temperature is higher than the
sealing temperature.

[0010]Following formation, the capsule is brought into contact with a
chilled liquid. The chilled liquid may be at a chilled liquid temperature
that is less than the fill material temperature and the sealing
temperature. In one embodiment of the instant invention, the gelatin is
cooled to a handling temperature so that it is sufficiently durable
preventing discernible faceting or flattening of the capsule during
further processing.

[0011]In another embodiment of the instant invention, the chilled liquid
may be a liquid deemed safe with respect to product contact by the Food
and Drug Administration. In one particular embodiment, the chilled liquid
is fractionated coconut oil. Once the capsule is substantially at the
handling temperature, the chilled liquid is separated from the capsule.
Following separation of the chilled liquid from the capsule, the capsule
is transferred into a dryer basket. The dryer basket reduces the water
content of the capsule so that the gelatin sheath is not substantially
sticky.

[0012]In another embodiment of the instant invention, the capsule may
contact a flowing chilled liquid layer. In yet another embodiment of the
instant invention, the flowing chilled liquid layer discharges the
capsule into a chilled liquid bath.

[0013]The system for cooling a hot-filled softgel capsule is designed to
cool the capsule formed by the rotary die machine. As previously
mentioned, the rotary die machine encases the fill material between two
gelatin bands by sealing the gelatin bands together at the sealing
temperature.

[0014]In one embodiment of the instant invention, a chilled liquid
conveyor tray is filled with the chilled liquid. The chilled liquid
conveyor tray is formed with a base, at least one sidewall, a chilled
liquid influent port, and a discharge edge. The sidewall is connected to
and surrounds a portion of the base. Thus, an interior surface and an
exterior surface are formed. The chilled liquid influent port extends
from the exterior surface to the interior surface to permit the chilled
liquid to flow into the chilled liquid conveyor tray. The discharge edge
connects the interior surface to the exterior surface so that the chilled
liquid, carrying the capsule, may flow out of the chilled liquid conveyor
tray.

[0015]The chilled liquid enters the chilled liquid conveyor tray through
the chilled liquid influent port. The chilled liquid forms a flowing
chilled liquid layer having a flowing chilled liquid layer depth and a
liquid layer flow rate inside the chilled liquid conveyor tray. The
capsule drops into contact with the flowing chilled liquid layer and heat
flows from the capsule to the chilled liquid. The chilled liquid and the
capsule flow across the discharge edge and out of the chilled liquid
conveyor tray.

[0016]In another embodiment of the instant invention, the chilled liquid
conveyor tray may include a chilled liquid layer forming base and the
sidewall has a proximal side, a distal side, and a back side. A chilled
liquid passageway is formed between the chilled liquid layer forming base
and the base. The chilled liquid flows through a chilled liquid influent
port into the chilled liquid passageway, through a chilled liquid layer
forming passageway and onto a chilled liquid layer forming surface.

[0017]In another embodiment, the system further includes a chilled liquid
tank filled with the chilled liquid. The chilled liquid tank holds a
chilled liquid bath with flow of the chilled liquid supplied from the
chilled liquid conveyor tray. In another embodiment of the instant
invention, the system for cooling a hot-filled softgel capsule may
include discharging the capsules directly into the chilled liquid tank
filled with the chilled liquid.

[0018]Thus, there is disclosed a method of producing a hot-filled softgel
capsule comprising the steps: encapsulating a fill material at a fill
material temperature by injecting the fill material between a first
gelatin band and a second gelatin band wherein the first gelatin band and
the second gelatin band are sealed at a sealing temperature such that a
capsule is formed; bringing the capsule into contact with a chilled
liquid wherein the liquid is at a temperature less than the fill material
temperature, and wherein said chilled liquid is a Food and Drug
Administration approved liquid; cooling the capsule with the chilled
liquid to a handling temperature such that the capsule does not
substantially deform, wherein the handling temperature is less than the
fill material temperature; and separating the capsule from the chilled
liquid, which comprises blowing a pressurized gas onto the capsule.

[0019]There is further disclosed a system for cooling a hot-filled softgel
capsule where a capsule is formed by encasing a fill material held at a
fill material temperature between two gelatin bands sealed together at a
sealing temperature, comprising: a chilled liquid conveyor tray formed
with a base, at least one sidewall, a chilled liquid influent port, and a
discharge edge, wherein the sidewall is connected to and surrounds a
portion of the base thereby forming an interior surface and an exterior
surface, the chilled liquid influent port extends from the exterior
surface to the interior surface, and the discharge edge connects the
interior surface to the exterior surface, wherein a chilled liquid enters
the chilled liquid conveyor tray at a chilled liquid temperature through
the chilled liquid influent port and forms a flowing chilled liquid layer
having a flowing chilled liquid layer depth and a liquid layer flow rate,
whereby the capsule contacts the flowing chilled liquid layer, heat flows
from the capsule to the chilled liquid, and the discharge edge discharges
the capsule and the chilled liquid out of the chilled liquid conveyor
tray.

[0020]Various objects and advantages of the present invention will become
apparent from the following detailed description when viewed in
conjunction with the accompanying drawings, which set forth certain
embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021]Without limiting the scope of the present invention as claimed below
and referring now to the drawings and figures:

[0022]FIG. 1 is a schematic of an embodiment of the instant invention, not
to scale;

[0023]FIG. 2 is an embodiment of the encapsulation assembly of the instant
invention, not to scale;

[0024]FIG. 3 is a schematic of an embodiment of the flowing chilled liquid
layer and an embodiment of the chilled liquid bath showing capsules being
transported with the flowing chilled liquid layer to the chilled liquid
bath, not to scale;

[0025]FIG. 4 is a perspective view of an embodiment of the chilled liquid
conveyor tray, not to scale; and

[0026]FIG. 5 is a cross-sectional view taken along section line 5-5 in
FIG. 4 of an embodiment of the chilled liquid conveyor tray.

DETAILED DESCRIPTION OF THE INVENTION

[0027]The method for producing and the system for cooling a hot-filled
softgel capsule of the instant invention enables a significant advance in
the state of the art. The preferred embodiments of the apparatus
accomplish this by new and novel arrangements of elements that are
configured in unique and novel ways and which demonstrate previously
unavailable but preferred and desirable capabilities. The detailed
description set forth below in connection with the drawings is intended
merely as a description of the presently preferred embodiments of the
invention, and is not intended to represent the only form in which the
present invention may be constructed or utilized. The description sets
forth the designs, functions, means, and methods of implementing the
invention in connection with the illustrated embodiments. It is to be
understood, however, that the same or equivalent functions and features
may be accomplished by different embodiments that are also intended to be
encompassed within the spirit and scope of the invention.

[0028]As seen in FIG. 1, the method for producing a hot-filled capsule may
include a primary mixing system (500) used to mix and homogenize one or
more fill materials (10). During the mixing and homogenization, the
primary mixing system (500) heats the fill material (10) to an elevated
temperature. For example, a heating bath may be coupled to a jacketed
tank. A heated fluid is circulated from the heating bath to the tank to
heat the fill material (10). As one skilled in the art will appreciate,
the temperature may be controlled with a temperature sensing device
coupled to a temperature controller which energizes a heat source.

[0029]With continued reference to FIG. 1, the fill material (10) is pumped
to a secondary mixing system (600) which may, for example, be a transfer
receiver. The secondary mixing system (600) may continue to perturb and
heat the fill material (10) to a fill material temperature prior to being
fed to an encapsulation pump head assembly (700). As one skilled in the
art will appreciate, other means may be used to heat the fill material
(10). Additionally, mixing the fill material (10) while heating may not
be necessary. For example, the fill material (10) may be locally heated,
but not mixed, immediately prior to entering the encapsulation pump head
assembly (700).

[0030]The encapsulation pump head assembly (700) is best seen in FIG. 2.
In this embodiment, the encapsulation pump head assembly (700) may
receive the fill material (10) from the secondary mixing system (600)
together with a first gelatin band (14) and a second gelatin band (16). A
pair of rotating dies encapsulates the fill material (10) between the
first and second gelatin bands (14, 16) forming a capsule (20) where the
fill material (10) is surrounded by gelatin. As one skilled in the art
will observe and appreciate, encapsulating the fill material (10) between
the first and second gelatin bands (14, 16) may require the gelatin to be
held at a sealing temperature to seal each half capsule to the other in
order to form the capsule (20). In one embodiment of the instant
invention, the fill material temperature is approximately the same as the
sealing temperature. In one particular embodiment, the fill material
temperature is between approximately 38 degrees Celsius and approximately
45 degrees Celsius. As the fill material temperature surpasses the
sealing temperature, the gelatin becomes progressively softer, that is,
the gelatin viscosity decreases, thus making uniform, aesthetic capsule
formation more difficult. As one skilled in the art will observe and
appreciate, gelatin viscosity may be a function of a number of factors,
including the type of gelatin and the temperature. For example, pork,
bovine, and fish gelatins do not exhibit the same viscosity relationship
with temperature.

[0031]With reference, once again to FIG. 1, in this embodiment of the
instant invention, once formed, the capsule (20) is brought into contact
with a chilled liquid (200). The chilled liquid (200) is at a chilled
liquid temperature. As one skilled in the art will observe and
appreciate, when the chilled liquid temperature is less than the sealing
temperature and the fill material temperature, heat is transferred from
the capsule (20) to the chilled liquid (200) causing the temperature of
the capsule (20) to decrease and the chilled liquid temperature to
increase. In one embodiment of the instant invention, the chilled liquid
temperature is between approximately minus 10 degrees Celsius and
approximately 10 degrees Celsius. However, the chilled liquid temperature
may be only slightly less than the sealing temperature or the chilled
liquid temperature may be colder than minus 10 degrees Celsius. In either
case, any temperature difference between the chilled liquid (200) and the
capsule (20) that cools the capsule (20) may be sufficient to prevent
permanent deformation. For example, as the temperature difference between
the fill material (10) and the chill liquid (200) increases, the cooling
rate of the capsule (20) increases. Large capsules may require higher
cooling rates to bring them from the fill material temperature to a
handling temperature within a sufficient time period to make their
manufacture cost effective. The chilled liquid temperature may be
adjusted by setting a target temperature on a chilled liquid cooling
system (400), best seen in FIG. 1. Furthermore, by maintaining the
gelatin sheath at the handling temperature, the capsule (20) may resist
external pressures exerted on the capsule (20). Thus, the capsule (20) is
less likely to form facets or flat spots as a result of contact with
external objects.

[0032]In one embodiment of the instant invention, the chilled liquid (200)
is a Food and Drug Administration approved non-aqueous liquid deemed safe
for human consumption. In one particular embodiment, the chilled liquid
(200) is fractionated coconut oil. Other representative non-aqueous
edible liquids suitable for chilling in the present invention include
oils such as linseed oil, sesame oil, mustard oil, castor oil, clove oil,
and vegetable and marine oils. In general, any material that does not
degrade or dissolve the soft capsule, is relatively inexpensive,
non-toxic, and easily removed from the soft capsule is suitable for use
in the present invention.

[0033]Once the capsule (20) is substantially at the handling temperature,
the chilled liquid (200) is separated from the capsule (20). In one
embodiment of the instant invention, a large percentage of the chilled
liquid (200) is removed from the capsule (20) with an air knife (352).
The air knife (352) forms a high pressure gas stream and directs the gas
stream onto the capsule (20). In one particular embodiment, the gas
stream is between approximately 10 pounds per square inch (psi) and
approximately 60 psi. As seen in FIG. 1, in another embodiment of the
instant invention, following separation of the chilled liquid (200) from
the capsule (20), the capsule (20) is transferred into a dryer basket
(800). The dryer basket (800) reduces the water content of the capsule
(20). As one skilled in the art will observe and appreciate, numerous
drying baskets may be implemented, depending on the water volume desired,
the production rate, and the capsule size, to name only a few factors. In
one embodiment of the invention, for example the embodiment seen in FIG.
1, successful production of capsules of the size range #4 to #40 with any
one or more of the common shapes, such as round, oval, or oblong with
heated fill materials, is possible.

[0034]In another embodiment, as seen in FIGS. 3 and 5, the chilled liquid
(200) may take the form of a flowing chilled liquid layer (170). The
flowing chilled liquid layer (170) is the chilled liquid (200) formed
into a flowing layer having a flowing liquid layer depth (172) and a
flowing liquid layer flow rate. As one skilled in the art will observe,
when the capsule (20) contacts the flowing chilled liquid layer (170)
heat is transferred from the capsule (20) to the chilled liquid (200). In
addition, while cooling the capsule (20), the flowing chilled liquid
layer (170) transports the capsule (20). In one particular embodiment of
the instant invention, the flowing liquid layer depth is between
approximately 0.5 inches and approximately 2 inches. As the capsule size
increases the flowing liquid layer depth (172) may also increase to help
cushion the capsule (20) as is falls from the encapsulation pump head
assembly (700) following formation.

[0035]In another embodiment of the instant invention, the flowing liquid
layer flow rate is between approximately 1 gallon per minute and
approximately 30 gallons per minute depending on the flowing liquid layer
depth (172) desired. Again, the capsule size may determine the liquid
layer flow rate. As with the flowing liquid layer depth (172), one
skilled in the art will appreciate that having a higher flowing, liquid
layer flow rate will generally provide a deeper flowing liquid layer
depth (172).

[0036]With reference to FIG. 3, in another embodiment of the instant
invention, the flowing chilled liquid layer (170) discharges the capsule
(20) into a chilled liquid bath (310) having a chilled liquid bath depth
(312). Once the capsule (20) departs the flowing chilled liquid layer
(170), the capsule (20) may be submerged in the chilled liquid bath (310)
where heat is transferred from the capsule (20) to the chilled liquid
bath (310). Similar to the flowing liquid layer depth (172), the chilled
liquid bath depth (312) may increase, as the capsule size increases and
as the fill material temperature increases, in order to provide
sufficient cooling to the capsule (20) and to prevent the capsule (20)
from deforming due to contact between the capsule (20) and another
capsule or rigid surface.

[0037]In another embodiment, immediately after the capsule (20) is formed
by the encapsulation pump head assembly (700), the capsule (20) is
brought into contact with the chilled liquid bath (310), as seen in FIGS.
1 and 3, held at a chilled liquid bath temperature. The chilled liquid
bath temperature is less than the fill material temperature so that when
the capsule (20) contacts the chilled liquid bath (310) heat is
transferred from the capsule (20) to the chilled liquid bath (310).

[0038]In one embodiment of the instant invention, a temperature drop from
the fill material temperature to the handling temperature may be as
little as 8 degrees Celsius for small capsules to bring them to the
handling temperature. In another embodiment, the capsule (20) may require
a temperature drop of at least 34 degrees Celsius. The capsule size also
influences the cooling period required. Therefore, in one embodiment of
the instant invention, the cooling period may be between approximately 30
seconds and approximately 120 seconds, depending on the capsule size,
fill material temperature, capsule production rate, and the chilled
liquid temperature. As one skilled in the art will appreciate, as the
capsule size increases, the thermal mass of the fill material (10)
increases relative to the mass of the gelatin. In turn, as the fill
material thermal mass increases, the cooling period may increase in order
to remove additional thermal energy to bring the capsule (20) to the
handling temperature.

[0039]The system for cooling a hot-filled softgel capsule (50) may be
designed to cool the capsule (20) formed by the rotary die machine. As
previously mentioned and as seen in FIG. 2, the rotary die machine
encases the fill material (10) between two gelatin bands by sealing the
gelatin bands together at the sealing temperature.

[0040]As seen in FIGS. 4 and 5, in one embodiment of the instant
invention, a chilled liquid conveyor tray (100) is filled with the
chilled liquid (200). The chilled liquid conveyor tray (100) is formed
with a base (120), at least one sidewall (110), a chilled liquid influent
port (150), and a discharge edge (160). The sidewall (110) is connected
to and surrounds a portion of the base (120). Thus, an interior surface
(130) and an exterior surface (140) are formed. The chilled liquid
influent port (150) extends from the exterior surface (140) to the
interior surface (130) to permit the chilled liquid (200) to flow into
the chilled liquid conveyor tray (100). The discharge edge (160) connects
the interior surface (130) to the exterior surface (140) so that the
chilled liquid (200) may flow out of the chilled liquid conveyor tray
(100). As one skilled in the art will observe and appreciate, the chilled
liquid conveyor tray (100) may be designed to allow the chilled liquid
(200) flow in a laminar or turbulent fashion. For example, various
devices or structure may be added to the chilled liquid conveyor tray
(100) to agitate the chilled liquid (200) thus creating a turbulent flow
pattern within the chilled liquid conveyor tray (100). On the other hand,
the dimensions of the chilled liquid conveyor tray (100) and the chilled
liquid flow may be adjusted to provide laminar flow of the chilled liquid
(200) within the chilled liquid conveyor tray (100). One skilled in the
art will also observe that the length of the chilled liquid conveyor tray
(100) may be designed to target a length of time the capsule (20) resides
in the chilled liquid conveyor tray (100). Besides the length, the
declination of the chilled liquid conveyor tray (100) may provide another
means to control the length of time the capsule (20) spends in the
chilled liquid conveyor tray (100).

[0041]During operation, as best seen in FIG. 5, the chilled liquid (200)
enters the chilled liquid conveyor tray (100) through the chilled liquid
influent port (150). The chilled liquid (200) forms the flowing chilled
liquid layer (170) having the flowing chilled liquid layer depth (172)
and the liquid layer flow rate inside the chilled liquid conveyor tray
(100). Once formed, the capsule (20) drops into contact with the flowing
chilled liquid layer (170). Heat flows from the capsule (20) to the
chilled liquid (200) while the capsule (20) is transported to the
discharge edge (160). The chilled liquid (200) and the capsule (20) flow
across the discharge edge (160) and out of the chilled liquid conveyor
tray (100).

[0042]As one skilled in the art will observe and appreciate, the chilled
liquid conveyor tray (100) may have many configurations and accomplish
cooling of the capsule (20) subsequent to its formation. For example, the
chilled liquid influent port (150) may be located in the sidewall (110)
rather than in the base (120). In another example, the discharge edge
(160) may be elevated from the base (120) forming a shallow weir to aide
in the formation of the flowing chilled liquid layer (170). In addition,
the chilled liquid conveyor tray (100) may be formed from a variety of
materials. By way of example and not limitation, the chilled liquid
conveyor tray (100) may be made of stainless sheet metal or plastic.

[0043]In another embodiment of the instant invention, the chilled liquid
conveyor tray (100) may be designed to fit to an existing rotary die
machine. As seen in FIGS. 4 and 5, the chilled liquid conveyor tray (100)
may include a chilled liquid layer forming base (180) and the sidewall
(110) has a proximal side (112), a distal side (114), and a back side
(116). The chilled liquid layer forming base (180) extends from the
proximal side (112) to the distal side (114) of the sidewall (110). A
chilled liquid passageway (190) is formed between the chilled liquid
layer forming base (180) and the base (120). The chilled liquid layer
forming base (180) has a chilled liquid layer forming surface (182) and a
chilled liquid layer forming passageway (184). The chilled liquid
passageway (190) provides fluid communication between the chilled liquid
influent port (150) and the chilled liquid layer forming passageway
(184), as best seen in FIG. 5. Thus, the chilled liquid (200) flows
through the chilled liquid influent port (150) into the chilled liquid
passageway (190). The chilled liquid (200) then flows through the chilled
liquid layer forming passageway (184) and onto the chilled liquid layer
forming surface (182) where the flowing chilled liquid layer (170) is
formed.

[0044]In another embodiment, the system (50) further includes a chilled
liquid tank (300) filled with the chilled liquid (200), as seen in FIG.
3. The chilled liquid tank (300) holds a chilled liquid bath (310) that
is in fluid communication with the chilled liquid conveyor tray (100) via
the discharge edge (160). During operation, the chilled fluid (200) and
the capsule (20) flow from the chilled liquid conveyor tray (100) to the
chilled liquid tank (300). The chilled liquid tank (300) has a capsule
transfer conveyor (320) having a transfer conveyor submerged portion
(330), a transfer conveyor inclined portion (340), and a transfer
conveyor chilled liquid removal portion (350).

[0045]The transfer conveyor submerged portion (330) captures the capsule
(20) on a capsule capturing portion (332) as the capsule (20) falls
through the chilled liquid (200). The transfer conveyor inclined portion
(340) transports the capsule (20) out of the chilled liquid bath (310) to
the transfer conveyor chilled liquid removal portion (350) where a
portion of the chilled liquid (200) is removed. The transfer conveyor
chilled liquid removal portion (350) may have the air knife (352)
positioned to direct pressurized gas onto the capsules (20). The air
knife (352) cleans a portion of the chilled liquid (200) from the capsule
(20). The transfer conveyor chilled liquid removal portion (350) may have
a discharge end (354). The capsule (20) is transported off the capsule
transfer conveyor (320) at a capsule discharge end (354). As one skilled
in the art will observe and appreciate, the transfer conveyor inclined
portion (340) may be designed to transport the capsules (20) vertically
out of the chilled liquid bath (310) rather than at along an inclination,
as seen in FIGS. 1 and 3.

[0046]As one skilled in the art will observe and appreciate, the cooling
period may be adjusted by altering the depth of the chilled liquid bath
(310) and the velocity of the capsule transfer conveyor (320). By
increasing the depth of the chilled liquid bath (310) or by decreasing
the velocity of the capsule transfer conveyor (320), the cooling period
may be increased. As one skilled in the art will observe, even while the
capsule (20) is in contact with the capsule transfer conveyor (320), the
capsule (20) may not deform even though the fill material (10) may still
be hot. In addition to providing a means for rapidly transferring heat
from the capsule (20), when the capsule (20) is submerged in the chilled
liquid (200), the chilled liquid (200) provides buoyancy to the capsule
(20). Thus, the weight of the capsule (20) does not rest entirely on the
capsule contact area with transfer conveyor (320) until the capsule (20)
is removed from the chilled liquid (200) at which point it has been
cooled to the handling temperature. The cooling period may require
adjustment depending upon the capsule size, the fill material
temperature, and the production rate.

[0047]In another embodiment of the instant invention, by redesigning the
encapsulation pump head assembly (700), the system for cooling a
hot-filled softgel capsule (50) may include discharging the capsules (20)
directly into the chilled liquid tank (300) filled with the chilled
liquid (200). Similar to an embodiment of the instant invention having
both the chilled liquid conveyor tray (100) and the chilled liquid tank
(300), the chilled liquid tank (300) may have the capsule transfer
conveyor (320) having the transfer conveyor submerged portion (330), the
transfer conveyor inclined portion (340), and the transfer conveyor
chilled liquid removal portion (350).

[0048]In one embodiment of the instant invention, the liquid layer flow
rate is between approximately 1 gallon per minute and 30 gallons per
minute. The liquid layer flow rate may be adjusted to account for the
productivity of the encapsulation machine, the capsule size, the
temperature of the fill material, the dimensions of the chilled liquid
conveyor tray (100), and the chilled liquid layer depth (172).

[0049]By way of example and not limitation, in one embodiment of the
instant invention, a #40 capsule is produced with the fill material
temperature of at least 38 degrees Celsius. After leaving the
encapsulation pump head assembly (700), the capsule (20) drops into the
liquid conveyor tray (100). The chilled liquid (200) is fractionated
coconut oil held at a temperature of approximately 0 degrees Celsius. The
capsule (20) is cooled as the capsule (20) is transported across the
discharge edge (160) out of the chilled liquid conveyor tray (100) and
into the chilled liquid bath (310). The capsule (20) sinks and gently
contacts the capsule transfer conveyor (320). The capsule transfer
conveyor (320) transports the capsule (20) out of the chilled liquid
(200) to the air knife (352) where the majority of the chilled liquid
(200) is removed. The cooling period from the capsule (20) first contact
with the chilled liquid (200) to exiting the chilled liquid bath (310) is
approximately 60 seconds. Moreover, no permanent deformation is apparent
in the #40 capsule.

[0050]In another example, the fill material temperature is greater than
approximately 35 degrees Celsius. Following encapsulation where the
gelatin is sealed around the fill material (10), the capsule (20) is
dropped into the chilled liquid conveyor tray (100). The chilled liquid
temperature is less than approximately 10 degrees Celsius. The capsule
(20) is transported into the chilled liquid bath (310) and emerges
between approximately 30 seconds and 60 seconds later. In another
example, the fill material temperature is at least approximately 38
degrees Celsius and the chilled liquid temperature is less than
approximately 0 degrees Celsius. Generally, as the fill material
temperature increases, the chilled liquid temperature decreases.

[0051]Numerous alterations, modifications, and variations of the preferred
embodiments disclosed herein will be apparent to those skilled in the art
and they are all anticipated and contemplated to be within the spirit and
scope of the instant invention. For example, although specific
embodiments have been described in detail, those with skill in the art
will understand that the preceding embodiments and variations can be
modified to incorporate various types of substitute and/or additional or
alternative materials, relative arrangement of elements, and dimensional
configurations. Accordingly, even though only few variations of the
present to invention are described herein, it is to be understood that
the practice of such additional modifications and variations and the
equivalents thereof, are within the spirit and scope of the invention as
defined in the following claims.

INDUSTRIAL APPLICABILITY

[0052]The system for producing a hot-filled softgel capsule answers a long
felt need for a system and method that is capable of encapsulating hot
fill material in gelatin. The system is used to produce small or large
softgel capsules of various shapes by injecting the heated fill material
between two bands of gelatin introduced between two rotating dies. The
present invention discloses a system and method that implements a chilled
liquid subsequent to encapsulation. The softgel capsules produced by the
rotating dies contact the chilled liquid thus transferring heat from the
capsule to the chilled liquid. The system and method thereby avoids some
of the aesthetic problems associated with encapsulating hot fill
materials with gelatin. The system of the present invention produces
softgel capsules that are safe for consumers, and the system is
environmentally friendly and cost effective.